Preparation of polyurethane foams containing a tris haloalkyl phosphate and adduct therefor



' 3,171,819 PREPARATION OF POLYURETHANE FOAMS CON- TAINING A TRIS HALOALKYL PHOSPHATE AND ADDUCT THEREFOR Thomas M. Powanda, Middlesex, NJ., assignor to Celanese Corporation of America, New York,

N.Y., a corporation of Delaware No Drawing. Filed Jan. 18, 1961, Ser. No. 83,379

17 Claims. (Cl. 2602.5)

This invention relates to the preparation of polyurethane foams and more particularly, to the production of stable adducts useful therein.

One of the necessary components used in the preparation of polyurethane foams is a compound containing free isocyanate (-NCO) radicals. This component can be a polyisocyanate, usually a diisocyanate, or a reaction product thereof containing free NCO radicals. Such a reaction product is sometimes called an adduct or a prepolymer and is usually formed with a polyol or a hydroxyl-terminated polyester or polyether. The second necessary component supplies reactive hydroxyl groups, derived from either a polyol or a hydroxyl-terrninated polyester or polyether. In most cases small quantities of water are added to the reaction mixture in order to react with some of the free NCO groups, forming CO in situ during the reaction. In many formulations, catalysts are also present. Optionally auxiliary foamers such as trichlorofluoromethane may be added.

Many problems are encountered in the preparation of successful and practical formulations. The handling of diisocyanates involves certain hazards and inconveniences. For this reason, it becomes preferable to work with adducts or prepolymers which supply reactive -NCO groups. Such adducts or prepolymers should be stable and should be in liquid form at a viscosity low enough for easy blending. Lack of stability may require the preparation of the adduct or prepolymer just prior to the production of the polyurethane foam.

In one useful method of producing polyurethane foams, a liquid hydroxyl-terminated polyester, such as a trimethylolpropanc-adipic acid reaction product, is reacted with a large excess of tolylene diisocyanate to produce an isocyanate-containing prepolymer which is reacted with additional hydroxyl-terminated polyester to produce the desired foam.

Accordingly one of the objects of this invention is to produce a useful adduct in liquid form having high stability characteristics by reacting an aromatic diioscyanate, such as tolylene diisocyanate, with trimethylolpropane.

A further object of this invention is the preparation of flame-resistant polyurethane foams. Still further objects will be apparent from the description which follows;

According to this invention, a stable adduct or prepolymer is formed from an arylene diisocyanate, such as tolylene diisocyanate, with certain triols, such as tri-' methylolpropane, in the presence of a tris-haloalkyl phosphate. The tris-haloalkyl phosphate is a liquid and acts as a substantially nonvolatile diluent. In producing the polyurethane foams, the stable adduct, is reacted with a hydroxyl supplying agent, which is a trifunctional polyol preferably containing ether linkages. Examples of the trifunctional polyols are trimethylolpropane, trimethylolpropane-polypropylene oxide condensation products and mixtures thereof. In another embodiment of this invention the hydroxyl supplying agents can be bifunctional United States Patent Patented Mar. 2, 191

polyols (diols) and can contain hydroxyl-terminal polyesters otherwise known in the polyurethane foam 1 In the description following hereinafter the adduc referred to are made from the following materials: arylene diisocyanates, (2) triols and (3) tris-haloall phosphates.

The preferred arylene diisocyanate is a tolylene isocyanate. Two isomers of the tolylene diisocyana are commercially available 2,4 tolylene diisocyanate a 2,6 tolylene diisocyanate. Commercially mixtures of two isomers are available in mixture ranges of about 8( 2,4 tolylene diisocyanate and 20% 2,6 tolylene diisoc nate. Other commercial mixtures contain 60% to 65 2,4 tolylene diisocyanate and 35% to 40% 2,6 tolylr diisocyanate. In the illustrative examples the 80/ mixture grade is used.

The adduct forming triols of this invention are 1 methylol triols, where all 3 methylol groups are connect to one carbon atom. They include: trimethylol-propa trimethylolethane and trimethylolbutane. Trimethyl propane is preferred.

The tris-haloalkyl phosphates used in the adduct f mation are illustrated by tris beta-chloroethyl phosphz tris beta-chloropropyl phosphate, tris dichloropro phosphate, tris dibromopropyl phosphate and tris ch10 bromo-propyl phosphate. Of these, tris beta-chloroetl phosphate is preferred.

'Tris-haloalkyl phosphates have been previously u: in polyurethane foam formulations to contribute flameproof qualities. In such formulations the ph phates act as plasticizers. In their novel use herein ct templated, they are used as stabilizing diluents duri adduct formation, resulting in excellent stability of 1 liquid adduct for periods as long as a year without cosity changes and also in a higher degree of ability crosslink in the. final foam preparation.

The reaction products of tolylene diisocyanate and 1 methylolpropane are hard and unusable masses. Addu with larger excesses of tolylene diisocyanate are mi fluid in general but they are not stable and solidify sho ly after preparation. If instead of trimethylolpropa alone, mixtures of trimethylolpropane and diol poly were used, with large proportions of diols present in I mixture, liquid products result; however, the functional of the polyol mixture is greatly reduced and the fir polymer foams are inferior in quality. Volatile solve1 also yield liquid products but presence of solvents cat numerous drawbacks, one of them being heat distorti and low dimensional stability at elevated temperatures.

In accordance with the present invention, it has be found that the use of a tris beta-chloroalkyl phosphate the adduct formation has. provided a diluent for the adduct systems rendering them stable over long peric of time.

In the following specific examples the effect of t tris beta-chloroalkyl phosphate on adduct formation effectively illustrated.

EXAMPLES I, H AND HI Three adducts were prepared by adding 3 mols of tol enediisocyanate to a 1 liter four neck reaction flm which was maintained under a nitrogen atmosphe Heat was applied until the temperature of the tolylene 1 isocyanate reached C. At this point 1 mol of t methylolpropane or the blend of trimethylolpropane-tr properties of the adducts formed.

' Table 1 Example I Example II Example III iolpropane 134 1a4. iiisocyanate 522 5Z2. .-chloroethyl pllOS- ('lDI) diisocyanate 261 391.

xcess TDI 5o 75. ris-beta-chloroethyl |te..

OH ratio 31 3/l 1 10.5/3. scosity at; 25 C. 148,000 10,600.

cc as made (fresh)-.. Clear Clear.

Floceulent.. Floccnlent. I White solid. White solid.

09 after 14 days. ee after 170 days. after 170 days at 25 1 shows the formulations of Examples Ito III be present in the composition, such as dimethylaniline, I

quinoline, pyridine, triamyline, tricthylamine, trip'ropylamine, N-methyl-morpholine, N-ethylmorpholine, diethylethanolamine, triethylenediamine, dimethylethanolamine. 'Silicone emulsifying agents are advantageously also present to control the uniformity of cell structure, as is known to those skilled in the art.

The adducts of this invention are illustrated below in rigid foam formulationswhere flame retardant properties of the foams formed are also shown. A comparison is also made with similar foam systems in which the adduct used does not contain tris'beta-chloroethyl phos phate, but the tris beta-chloroethyl phosphate is added to the foaming compound formulation just prior to use.

In the following example, a prepolymer is made with "Pluracol TP-440 which is a propylene oxide condensation product with trimethylolpropane having a general formula: 1

Thevalues for x, y and z are approximately equal. The molecular weight is about 400, the hydroxyl number is about 400, the equivalent weight is 137, percent hydroxyl about 12.4, number of atoms for each branch is 8..

Example IV shows a prepolymer formulation with TP440.

EXAMPLE IV ii i 1 'lP-440 si z 8) Tolylene diisocyauate.. 2,679.6} NCO] on /19} F I on (C) Pluracol TP440 658. 2

n be seen from Table 1, Examples II and III did :1 satisfactory products despite the fact that the )f Example III was made with excess tolylene dite. The product of Example I is a stable liquid and illustrates the product of this invention. xcess isocyanate percentage in the adducts of this [1 may range from about 25% to about 100%. nurn of 50% 'is' preferredf-There is rarely any ;e in using excess over The tris-haloalkyl te content of the adduct may range from about about 40%. The. preferred range is from about about 30%. nitial tolylene diisocyanate and the trimethylolin the trimethylolpropane-tris-beta-chloroethyl to blend are in approximately stoichiometric :s and the free isocyanato groups of the adduct rom the excess tolylene diisocyanate, which is fter completion of the exothermic reaction. It 1 found that other possible changes of order of result in less favorable products, e.g.', if all the diisocyanate is present in the reactor first, or rlylene diisocyanate is added to the trimethylol- -trisbeta-chloroethyl-phosphate blend, the resultlct has less desirable properties than the product .ple I. .dducts of -this invention are useful in polyuream compositions as NCO-supplying agents. iupplying agents, polyols (diols or triols) or hy- :rminated polyesters, known in the art, can be he adducts can be used in formulating rigid or d or flexible polyurethane foams. Catalysts may The prepolymer was made in accordance with the following procedure:

(1) Tolylene diisocyanate (B) was charged to the reactor and TP-440 (A) was added slowly. The reaction was exothermic and the temperature rose toabout 60 C.

(2) After all of (A) was added, the temperature was held for one hour at 60 C.

(3) The second portion of TP-440 (C) was added slowly. The reaction was exothermic and the. reaction mixture was kept at C. while using external cooling.

(4) The temperature was held at 90 C. for one hour, after all of (C) was added.

'(5) The mixture was cooled to room temperature and discharged.

Constants of prepolymer:

Viscosity at 25 C. cps 20,200 Percent free isocyanate pcrcent 22.1

With the adduct of Example I and with the prepolymer of Example IV, rigid polyurethane foam compositions were prepared. The foams with the adduct of Example I were formulated at tris beta-chloroethyl phosphate contents of 15% and 20%, respectively. The foams with the prepolymer of Example IV were formulated at the same phosphate content, the same free isocyanate content and at a free isocyanate-water ratio of 1/1. In one case no tris beta-chloroethyl phosphate was added in order to obtain a control free of this compound. The formulations were cured for two weeks at room temperature.

Flammability was determined in accordance with the T able 2 Foam A Foam B Foam C FoznnD Foam E Adduct 01 Ex. I. None 110. 8 None 150. 2 Nero Addnct of Ex. IV 106. 5 46. 141. 0. 6 133. 0 50/50 wt. ratio of T1- 440 and trimethylolpropane 33. 5 34. 2 '28. 4 d4. 5 26. 7 Tris licta-ohloroethyl hosphate None None 30. 0 None 40. 0 Water 3. 4 3.1 2. 9 2. 9 2. 7 Silicone emulsifying agelit 0.8 0.8 0.7 0.8 0.6 Dinuthylethnnolmn inev 2. 0 2. 0 1. 7 2. 0 1. 0 Percent. Tris helmoliloroe-th l i rosplmle."Kind..." None 15.0 15.]? 20.18 20.18 Mixing time (secs.) 10 10 Rise time truins.) 1.6 1.5 3.0 1.5 3.0 Setv time (mins 3. 5 3. 5 8.0 3. 5 8.0

Table 3 Percent Average Average Average Number of Foam Tris Betaamount Burning Burning samples No. Chloro- Consumed Time Rate tested ethyl (ins) (seconds) (in/min.)

None 4 16. 6 14. 7 10 1 0. 6 10. 4 3. 7 7 15 1 1.3 )17 2 4.3 20 20 1 2. 4 37. 3 4.1 7

1 Self-extinguishing.

2 Non-burning.

A material is considered non-burning if the specimen does not ignite on two attempts. It is considered selfextinguishing if the specimen does not burn to the 4-inch mark after the first or second ignition.

The data of Tables 2 and 3 show the comparison of the flame retardant properties of the adduct of Example I with an equivalent foaming system where tris beta-chloroethyl phosphate was either not incorporated, or was added just prior to foaming during the blending of the foaming ingredients. The control Foam A showed considerable burning damage with high figures for amount consumed, burning time and burning rate. At 15% level of tris betachloroethyl phosphate both Foams B and C were judged self-extinguishing, however, Foam B containing the adduct of Example I showed lower amount of amount consumed, lower burning time and lower burning rate. At 20% level of the phosphate Foam D containing the adduct of Example I was completely non-burning whereas Foam E where the phosphate was incorporated as such, prior to the foaming, reached only the self-extinguishing stage, showed a considerable amount consumed, a long burning time and a comparatively high burning rate. The flame retardant properties of the adduct were of considerable magnitude.

If the adducts of this invention are used for their flame retardant properties, the foaming ingredients should be formulated to contain at least about 10% tris-haloalkyl phosphate in the polyurethane foam. The percentage of the phosphate does not need to be higher than 20% to achieve non-burning qualities. Higher percentages may be used for special purposes or to meet requirements of the formed foam other than flame retardancy.

It is to be understood that the foregoing detailed description is given merely by way of illustration and that many variations may be made therein without departing from the spirit of my invention.

Having described my invention what I desire to secure by Letters Patent is:

1. A liquid, storage-stable adduct with high functionality and having free isocyanato groups useful in the production of polyurethane foams, said adduct being the product of the reaction, in the presence of a tris-haloalkyl phos phate, of an arylene diisocyanatc and a trimethylol triol having three methylol groups connected to a single carbon atom.

2. The duct of claim 1 in which the trimethylol trit having three methylol groups connected to a single carbo atom is a trimcthylolalkane carrying the three nicthyk radicals attached to :1 single carbon atom.

3. The adduct of claim 1 wherein the trimethylol trit having three methylol groups connected to a single carbo atom is trimethylolpropane.

4. The adduct of claim 1 wherein the arylene diisoc} anate is tolylene diisocyanate.

5. A liquid, storage-stable adduct with high functior ality and having free isocyanato groups useful in th production of polyurethane foams, said adduct being th reaction product of an arylene diisocyanate, a trimethyk triol having three methylol groups connected to a sing] carbon atom and tris beta-chloroethyl phosphate.

6. The adduct of claim 5 wherein the tris beta-chlorc ethyl phosphate is present in the adduct in the pereentag range of from about 15 percent to 40 percent, by weigh based on the total weight of the adduct.

7. The adduct of claim 5 wherein the tris beta-chlorr ethyl phosphate is present in the adduct in the weigl percentage range of from about 25 percent to about 3 percent based on the total weight of the adduct.

8. The adduct of claim 5 containing free isocyanat groupings from about 14% to about 25%, by weigh and being based on the total weight of the adduct.

9. A process for the production of a liquid, stab] adduct with high functionality and useful as an isocyanat supplying component of polyurethane foam composition comprising the steps of reacting about one mol of trimethylol triol having three methylol groups connecte to a single carbon atom with about three mols of an ary ene diisocyanate in the presence of tris-haloalkyl phosphal and then reacting additional arylene diisocyanate wit the product of the first reaction step.

10. The process of claim 9 in which the arylene d isocyanato is tolylene diisocyanate.

11. The process of claim 10 in which the trimethyh triol having three methylol groups connected to a sing. carbon atom is trimethylolpropane.

12. The process of claim 10 in which the tris-haloalkj phosphate is tris beta-chloroethyl phosphate.

13. The process of claim 10 wherein the reaction the first step is carried out at about 65 C.

14. The process of claim 10 in which the tris haloalk phosphate is used in proportions ranging from about 1 percent to about 40 percent of the total weight of tl adduct.

15. The process of claim 10 wherein the arylene d isocyanate is tolylene diisocyanate, the trimethylol tri having three methylol groups connected to a single ca bon atom is trimethylolpropane and the tris-haloalk phosphate is tris beta-chloroethyl phosphate.

16. In the process for the preparation of polyurethar foams by the reaction of an isocyanate, an active hydro) containing compound selected from the group consistin of polyesters and polyethers and a blowing agent, tl'. improvement which comprises using as the isocyana' supplying agent, a liquid, storage stable adduct which the reaction product of an arylene diisocyanate, a tr methylol triol having three methylol groups connecte to a single carbon atom and a tris-haloalkyl phosphate. 17. The process of claim 16 wherein the arylene d isocyanate is tolylene diisocyanate, the trimethylol tllt having three methylol groups connected to a single carbo atom is trimethylolpropane and the tris-haloalkyl pho phate is tris beta-chloroethyl phosphate.

References Cited in the file of this patent UNITED STATES PATENTS 2,956,031 Khawam Oct. 11, 196 2,981,700 Parker et. al. Apr. 25, 196 3,076,770 Saunders et al. Feb. 5, 196

I FOREIGN PATENTS 205,456 Australia Ian. 4, 

16. IN THE PROCESS FOR THE PREPARATION OF POLYURETHANE FOAMS BY THE REACTION OF AN ISOCYANATE, AN ACTIVE HYDROXY CONTAINING COMPOUND SELECTED FROM THE GROUP CONSISTING OF POLYESTERS AND POLYETHERS AND A BLOWING AGENT, THE IMPROVEMENT WHICH COMPRISES USING AS THE ISOCYANATE SUPPLYING AGENT, A LIQUID, STORAGE STABLE ADDUCT WHICH IS THE REACTION PRODUCT OF AN ARYLENE DISOCYANATE, A TRIMETHYLOL TRIOL HAVING THREE METHYLOL GROUPS CONNECTED TO A SINGLE CARBON ATOM AND A TRIS-HALOALKYL PHOSPHATE. 